Systems and methods for liquid-based lint collection

ABSTRACT

A screen-free, liquid-based lint collection system is disclosed. The system comprises an initial air-lint conduit. The air-lint conduit is coupled to a lint collection reservoir. The system further comprises a spray assembly and a sensor. The spray assembly is configured to spray a liquid into the lint-collection reservoir. The sensor monitors the level of the liquid collected in the lint-collection reservoir.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of priority under 35 USC§119(e) to U.S. Provisional Patent Application 62/096,326 filed Dec. 23,2014, which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The field of the invention relates to lint collection systems and moreparticularly to liquid-based lint collection systems for clothes dryers.

SUMMARY OF THE INVENTION

According to one aspect of the present disclosure, a screen-free,liquid-based lint collection system is disclosed. The system comprisesan initial air-lint conduit. The air-lint conduit is coupled to a lintcollection reservoir. The system further comprises a spray assembly anda sensor. The spray assembly is configured to spray a liquid into thelint-collection reservoir. The sensor monitors the level of the liquidcollected in the lint-collection reservoir.

According to another aspect of the present disclosure, a screen-free,liquid-based lint collection system is disclosed. The system comprises asystem chamber, having an inlet that receives an air-lint combination.The chamber defines an interior having a reservoir section and an airflow area. The system further comprises an interior conduit, a sprayassembly, and a sensor. The interior conduit is disposed within thesystem chamber. The spray assembly sprays liquid into the reservoirsection, and the sensor monitors the level of the liquid collected inthe reservoir section.

According to yet another aspect of the present disclosure, a clothesdryer is disclosed. The clothes dryer comprises an outer body having ahatch door and a tumbler disposed within the outer body coupled to thehatch door. The system further comprises a screen-free, liquid-basedlint collection system. The lint collection system comprises an initialair-lint conduit fluidically coupled to the tumbler. The lint collectionsystem also comprises a lint-collection reservoir coupled to the initialair-lint conduit and a spray assembly that sprays liquid into thelint-collection reservoir. A sensor monitors the level of the liquidcollected in the lint-collection reservoir.

These and other features, advantages, and objects of the presentinvention will be further understood and appreciated by those skilled inthe art by reference to the following specification, claims, andappended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of illustrating the invention, exemplary embodiments areshown in the drawings. It should be understood, however, that theinvention is not limited to the precise arrangements andinstrumentalities shown. The following detailed description of theinvention, will be better understood when read in conjunction with theappended drawings.

FIG. 1 is a schematic of a screen-free, liquid-based lint collectionsystem shown in a front view of a partially assembled clothes dryerconfigured to deliver a filtered air to a blower;

FIG. 2 is a cross-sectional view of the lint collection system shown inFIG. 1, taken along line 2-2 of FIG. 1;

FIG. 3 is a partial front perspective view of a clothes dryerdemonstrating a lint collection system;

FIG. 4 is a front view of the clothes dryer demonstrating a lintcollection system;

FIG. 5 is a partial top view of a lint-collection reservoir of a lintcollection system;

FIG. 6 is a partial rear perspective view of the lint collection systemconfigured to receive an air-lint combination from an outlet of ablower;

FIG. 7 is a schematic of a screen-free, liquid-based lint collectionsystem of FIG. 6 shown in a partial rear view;

FIG. 8 is a partial side cross-sectional view of the lint collectionsystem, taken along line VII-VII of FIG. 7;

FIGS. 9A and 9B are projected side views of an air-lint conduitincorporated into the lint collection system;

FIG. 10 is a flowchart of a method of operation used for the lintcollection systems disclosed herein;

FIG. 11 is a flowchart of a method of operation used for the lintcollection systems disclosed herein;

FIG. 12 is a flowchart of a method of operation used for the lintcollection systems disclosed herein; and

FIG. 13 is a schematic diagram of a control system for a lint collectionsystem in accordance with the disclosure.

DETAILED DESCRIPTION

Reference will now be made in detail to the embodiments of the inventionillustrated in the accompanying drawings. Wherever possible, the same orlike reference numbers will be used throughout the drawings to refer tothe same or like features. It should be noted that the drawings are insimplified form and not drawn to a precise scale.

In reference to the disclosure herein, for purposes of convenience andclarity only, directional terms such as top, bottom, above, below,proximal, distal, and transverse, are used with respect to theaccompanying drawings. Such directional terms used in conjunction withthe following description of the drawings should not be construed tolimit the scope of the invention in any manner not explicitly set forthherein. Unless specifically set forth herein, the terms “a”, “an” and“the” are not limited to one element but instead should be read asmeaning “at least one”. The terminology includes the words noted above,derivatives thereof and words of similar import. It should also be notedthat the terms “first”, “second”, “third”, “upper”, “lower”, and thelike may be used herein to modify various elements. These modifiers donot imply a spatial, sequential, or hierarchical order to the modifiedelements unless specifically stated.

It will be appreciated by those skilled in the art that changes could bemade to the embodiments described above without departing from the broadinventive concept thereof. It is understood, therefore, that thisinvention is not limited to the particular embodiments disclosed, but itis intended to cover modifications within the spirit and scope of thepresent invention as defined by the appended claims.

Lint, also known as fluff, is generally defined as the visibleaccumulation of fibers, hair, dust, and other materials that comes fromclothing. Certain materials used in clothing manufacture, e.g., cotton,linen, and wool, contain very short fibers, are easily released whileworn due to movement, frictional interference, etc. The short fibersattach to the outer and inner surfaces of clothing—where lint buildupoccurs.

Dryer lint is a type of lint, which results when clothes are tumbledduring a drying cycle. Tumbling of clothes acerbates the release ofclothing fibers—resulting in additional accumulation of lint. Generally,when clothes are dried using a clothes dryer, lint will accumulate.

In a traditional clothes dryer, the accumulation of dryer lint iscaptured in a designated area, using a screen filter. It is recommendedthat a screen filter be cleaned after every drying cycle for dryersafety and efficiency. Dryer lint is highly flammable and if notregularly removed from the dryer, the potential for a fire hazardincreases.

In a typical household, the average clothes dryer will dry almostfive-hundred (500) loads of laundry each year. During each load dryerlint accumulates. And although regular and frequent removal of dryerlint helps, most screen filters only capture a low percentage of dryerlint. For dryers used in commercial settings, however, the cleaning oflint filter screens is typically not very frequent, further increasingthe risk of a fire, while simultaneously decreasing dryer performance.

In addition to causing a fire hazard, dryer efficiency will decreasewhen the accumulation of dryer lint is not regularly and frequentlyremoved. But, just the use of a lint filter screen in and of itself,although very useful in preventing fires, also negatively affects dryerefficiency. Lint filter screens restrict air flow within a dryer.Moreover, as lint accumulates on a lint screen filter, airflow isfurther restricted. And when dryer efficiency decreases, the longer ittakes for clothes to dry.

To address the various issues raised by dryer lint accumulation, it maybe useful to provide an improved system for lint removal. Such a systemmay be sold as an aftermarket item and are external to the clothesdryer. The disclosure provides for a screen-free, liquid-based lintcollection system for clothes dryers. The present invention fulfillsvarious needs, and provides further related advantages as describedbelow.

Disclosed herein is a screen-free, liquid-based lint collection systemand methods to be utilized in clothes dryers. Each type of lintcollection system disclosed herein collects lint in such a way that theamount of collected lint has a lessened effect on airflow and/or dryerperformance when compared to clothes dryers that include traditionallint screen filters. The disclosed systems may also flush and replenishliquid automatically.

In contrast to other liquid-based lint collection systems, the lintcollection systems described herein may eliminate a need for a screenfilter and automatically clean or flush lint. The lint collectionsystems may be incorporated as an integral component of a clothes dryerand allow exhausted air to be vented outdoors. Finally, the disclosedlint collection systems may provide for improved efficiency and may notadversely affect dryer performance.

Referring to FIGS. 1-5, views of an exemplary embodiment of ascreen-free, liquid-based lint collection system 10 are shown. The lintcollection system 10 is configured to filter lint 6 from an air-lintcombination 1 a upstream from a fan/blower 30 (FIG. 2). The lintcollection system 10 may be disposed within a clothes dryer 2 in adesignated area 3 of the clothes dryer 2. The clothes dryer 2 mayinclude any and all elements typically included in clothes dryers thatdry clothing, particularly clothes dryers using a combination of air andtumbling. Components of the clothes dryer 2, therefore, may include atumbler 4, an outer body 5, a hatch door 8 a (FIGS. 3 and 4), an accessdoor 8 b (FIGS. 3 and 4), and one or more control systems 9, 270 for thedryer 2 and/or the lint collection system 10. The control system 270 forthe lint collection systems is further discussed in reference to FIG.13.

In an exemplary embodiment, the lint collection system 10 may bepositioned in a designated area 3, accessible via the access door 8. Thedesignated area 3 may be located under the tumbler 4 of the dryer 2. Inthis arrangement, the air-lint combination 1 a may efficiently pass intothe lint collection system 10 such that the lint 6 may be filtered fromthe combination 1 a prior to passing into the fan/blower 30, which mayalso be located in the designated area 3.

The lint collection system 10 includes an initial air-lint conduit 12,which is fluidically coupled to the tumbler 4 such that the air-lintcombination 1 a contained within the tumbler 4 flows to the conduit 12.The lint collection system 10 further includes a lint-collectionreservoir 14, which is coupled to the initial air-lint conduit 12. Thereservoir 14 may be supplied with a liquid 7 from at least one nozzle20. The liquid 7 may be delivered to the reservoir and serve as afiltration mechanism to remove the lint 6 from the air-lint combination1 a and flush the lint 6 from the reservoir 14.

As the air-lint combination 1 a is directed into the reservoir 14, thelint 6 adheres to a surface 7 a of the liquid 7 accumulated in thereservoir 14. The lint may also accumulate against the inner walls 16 ofthe reservoir 14. During use of the system 10, the liquid 7 may bedirected into the reservoir 14 via a spray assembly 18. In an exemplaryembodiment, the at least one nozzle 20 of the spray assembly 18 maycorrespond to a plurality of nozzles 20 (e.g. 4 nozzles). Asillustrated, each of the nozzles 20 may be supplied with the liquid 7via hoses 22, a valve 24, and an inlet connection 26 of the sprayassembly 18.

In an exemplary embodiment, the liquid 7 is water. However, otherliquids may similarly be utilized in the system 10. For example, in someembodiments, a solvent or liquid solution may be utilized. Additionally,the liquid 7 may contain additives that facilitate the degradation ofthe lint 6.

After the collected liquid 7 b is drained, the liquid 7 may continue tobe supplied into the reservoir 14 via the nozzles 20 to rinse off lint6, which has accumulated against the inner walls 16. The rinsing actionmay force the lint 6 to flow to the surface 7 a, such that the lint 6adheres to the surface 7 a of the collected liquid 7 b at the bottom ofthe reservoir 14. The level of the surface 7 a of the collected liquid 7b may be controlled by the system 10 to ensure that the level of thecollected liquid 7 b is maintained at a predetermined range for thefiltering of the lint 6. A base 27 of the reservoir 14 may be pitched.In an exemplary embodiment, a pitch angle 13 of the base 27 may rangefrom about 5°-10° and may provide for improved draining of the reservoir14.

In order to maintain the level of the surface 7 a of the collectedliquid 7 b, the system 10 may comprise a switch/sensor 28. When thelevel of the collected liquid 7 b reaches a first predeterminedthreshold, the valve 24 will close to stop the supply of the liquid 7.Conversely, if the level of the collected liquid 7 b is not sufficientfor operation, the switch/sensor 28 will detect that the level of thecollected liquid 7 b is below a second predetermined threshold, and thesystem 10 will control the valve 24 to open. Data outputted by theswitch/sensor 28 is received by a control system 9 for the dryer 2and/or a control system 270 for the lint collection system 10.

The switch/sensor 28 may correspond to various forms of switching and/orsensory devices. Some devices may include a float, a sonic sensor, ahydrostatic sensor (e.g. a displacer, a bubbler, a pressure transducer,etc.), a magnetic level gauge, and/or various level sensing devices. Theswitch/sensor 28 may be disposed in an auxiliary column 29 a in fluidcommunication with the collected liquid 7 b via a sight glass tube 29 b.The auxiliary column 29 a may correspond to a sight glass 29 cconfigured to provide a visual indication of the level of the surface 7a of the collected liquid 7 b. The auxiliary column 29 a may be securedto the reservoir via a mounting bracket 29 d. In this configuration, theoperation system 10 may be configured to accurately control the level ofthe surface 7 a and may be verified visually.

With the level of the surface 7 a of the collected liquid 7 bcontrolled, the system 10 may effectively filter the lint 6 from theair-lint combination 1 a. As the air-lint combination 1 b passes overthe liquid 7 in the reservoir 14, a significant portion of the lint 6from the air-lint combination 1 a is trapped by the liquid 7. In thisway, a filtered air 1 b is produced. The filtered air 1 b is routed tothe fan/blower 30 via an air passageway 32 positioned between theair-lint conduit 12 and the fan/blower 30, as shown in FIG. 2. After thefiltered air 1 b has been routed through the fan/blower 30, the air 1 bexits through an outlet conduit 38 to the atmosphere A, outside of thedryer 2.

With respect to the collected liquid 7 b and lint 6, a pump 34 iscoupled to the lint collection reservoir 14 to pump away lint 6contained in the collected liquid 7 b that accumulates into thereservoir 14. The pump 34 is coupled to the reservoir 14 by adrain/suction tube 35. The pump 34 is also connected to a discharge port36 that discharges the lint 6 to a waste receptacle (not shown). Powerto the pump 34 and/or to the control system 9, 270 may be supplied via aseparate power supply or directly from the dryer wiring itself.

Referring now to FIG. 5, the nozzles 20 of the system 10 may beconfigured to flush the lint 6 from the inner walls 16 of the reservoir14 via a vortex action 40. The vortex action 40 may be produced by aflow of the liquid 7 entering the reservoir 14. In an exemplaryembodiment, each of the four nozzles 20 may pass through a wall 42 ofthe reservoir 14 proximate a corner portion 44. Each of the nozzles 20may be directed in complementary directions within the reservoir 14 toproduce a rotational flow direction 46 of the collected liquid 7 b. Forexample, a sprayed liquid 7 c may be projected from each of the nozzles20 to generate a clockwise rotation or a counter-clockwise rotation 48of the vortex action 40. The counter-clockwise rotation 48 of the vortexaction 40 is shown in FIG. 5 as an exemplary embodiment.

The vortex action 40 produced in the reservoir 14 may provide for thedirectional flow of the lint 6 in the collected liquid 7 b. Thedirectional flow may enhance the efficiency of a removal of the lint 6from the reservoir by pushing the lint 6 toward a central portion 50 ofthe reservoir 14. In this configuration, the lint 6 captured in thecollected liquid 7 b may flow toward the drain/suction tube 35. The lintcollection system 10 may provide for the efficient collection of thelint 6 that is captured in the reservoir 14 such that the lint 6 iseffectively removed from the reservoir 14 by the pump 34.

Referring back to FIG. 2, as discussed above, the air-lint combination 1a is directed into the reservoir 14 from the tumbler 4. To ensure thatthe air-lint combination 1 a enters the reservoir 14 efficiently, aninlet elbow 52 may be utilized to interconnect the tumbler 4 and thereservoir 14. The inlet elbow 52 may have a substantially rectangularform and correspond to the conduit 12 extending into the reservoir 14.Additionally, the inlet elbow 52 may comprise at least one angled orcontoured wall 54 configured to direct the flow of the air-lintcombination 1 a across the surface 7 a. The efficient delivery of theair-lint combination 1 a into the reservoir may include introducing theair-lint combination 1 a over the surface 7 a without generatingsplashing of the collected liquid 7 b.

The efficiency of the passage of the air-lint combination 1 a into thereservoir may also be controlled by an inlet space 56 between an endportion 58 of the inlet elbow 52 relative to the level of the surface 7a. The inlet space 56 may vary based on the proportions of the inletelbow 52 relative to the rate of circulation of the air in the tumbler 4and the corresponding flow rate of the air-lint combination 1 a throughthe inlet space 56. In an exemplary embodiment, the inlet elbow 52 mayextend at least partially into the reservoir 14 and form a reservoirspace between the inlet elbow 52 and the inner walls 16 of the reservoir14. In this configuration, the air-lint combination 1 a may enter thereservoir 14, pass over the surface 7 a of the collected liquid 7 b, andthe filtered air 1 b may be passed outward through the reservoir space.

Referring to FIGS. 6-9B, an embodiment of a screen-free, liquid-basedlint collection system 110 is shown. The lint collection system 110 isconfigured to filter lint 6 from an air-lint combination 1 a downstreamfrom a fan/blower 130 (FIG. 8). The system 110 collects lint 6 after anair-lint combination 1 a leaves a fan/blower 130 disposed within thedryer 2. Reference numerals of the second embodiment are distinguishablefrom those of the first embodiment by a factor of one-hundred (100), butotherwise indicate the similar elements as indicated in the embodiment10, except as otherwise specified. The description of certainsimilarities between all embodiments described herein may be omitted forthe sake of clarity, and, therefore, is not limiting.

In the lint collection system 110, after the air-lint combination 1 apasses through the tumbler 4, the air-lint combination 1 a flows overcollected liquid 7 b before flowing through a specially designedinterior conduit 182 or an outlet elbow. The specially designed interiorconduit 182 includes a stepped entry region 184, an angled transitionregion 186, and an outlet region 188. As the air-lint combination 1 apasses over the collected liquid 7 b, lint 6 collects onto the liquidsurface and may accumulate or “stick” onto inner surfaces 190 of theinterior conduit 182.

The system 110 may be disposed within a clothes dryer 2 in a designatedarea 3 of the clothes dryer. The lint collection system 110 may becontained within a system chamber 170. The system chamber 170 mayinclude a top 172 having a front section 172 a and a rear section 172 b,sidewalls 174 a, 174 b, a base 176, a front wall 178 a, and a rear wall178 b. The interior 180 of the system chamber 170 acts as both areservoir and an air passageway for the air-lint combination 1 a.Specifically, the chamber 170 includes a bottom reservoir section 114and an air flow area 132 such that the air-lint combination 1 a flowsthrough the system 110 and filtered air 1 b flows out into an outletexhaust line 192 and thereafter to the atmosphere A, as shownparticularly in FIG. 8.

During use of the system 110, sprayed liquid 7 c is sprayed into theinterior conduit 182 via a spray assembly 118 routed through the rearsection 172 b of the top 172. The spray assembly 118 includes at leastone nozzle 120 connected to a supply of the liquid 7 via a hose 122, avalve 124, and an inlet connection 126. The at least one nozzle 120 maycorrespond to a plurality of nozzles 120 a configured to generate thevortex action 40 as discussed in reference to FIG. 5. The liquid sprayedfrom the nozzles 120 may rinse lint 6 from the inner walls 116 of thereservoir 114.

The system 110 may comprise a nozzle 120 b disposed in the interiorconduit 182. The nozzle 120 b may be configured to rinse the lint 6accumulated against the inner surfaces 190 of the interior conduit 182.In this configuration, the lint 6 accumulated against the inner surfaces190 may be deposited on the surface 7 a of the collected liquid 7 b atthe bottom of the reservoir section 114. The nozzle 120 b may beconfigured to produce the sprayed liquid 7 c, having at least a120-degree spray angle, as shown in FIG. 6. In this configuration, thenozzles 120 may be configured to significantly remove the lint 6 fromthe inside of the reservoir 182 to prevent buildup.

The system 110 may also comprise a switch/sensor 128 configured tomonitor the level of the collected liquid 7 b within the system 110.When the level of the collected liquid 7 b has reached a predeterminedthreshold, the valve 124 will close. Conversely, if the level of thecollected liquid 7 b is not sufficient for operation of the system, thevalve 124 will open. This procedure will repeat, as determined by thecontrol system 9 for the dryer and/or the control system 270 for thelint collection system 110. A base 127 of the reservoir 114 may bepitched. In an exemplary embodiment, a pitch angle 13 of the base 127may range from about 5°-10° and may provide for improved draining of thereservoir 114.

With respect to the collected liquid 7 b and lint 6, a pump 134 (FIG. 6)is coupled to the system chamber 170 via a drain/suction tube 135 topump away lint 6 contained in the collected liquid 7 b. Thedrain/suction tube 135 is connected to a discharge port 136 thatdischarges the lint to a waste receptacle (not shown). Power to the pump134 and/or to the control system 9 of the dryer 2 or the lint collectionsystem 110 can be supplied via wiring.

Referring to FIG. 9 a detailed view of the interior conduit 182 is shownthat further demonstrates the stepped entry region 184 and the angledtransition region 186. The interior conduit has an overall conduitheight CH, and conduit width, CW₁. The stepped entry region 184 includesa plurality of stepped sections, including but not limited to a firststepped section 194 and a second stepped section 196. The first steppedsection 194 may be defined with respect to a predetermined height of theliquid, LH, a first stepped section height H₁, where LH is generallymeasured from the bottom 176 of the system chamber 182 to the surface ofthe first stepped section 194.

The second stepped section 196 may be defined with respect to the firststepped section 194 and a second stepped section height H₂, wherein H₂is generally measured from the bottommost edge 200 of the second steppedsection 196. The first stepped section 194 may also be defined withrespect to a first side width S₁ measured from a rear edge 202 of theinterior conduit 182 to a first edge 204. The second stepped section 196is further defined with respect to a second side width S₂ measured fromthe first edge 204 to an inner edge 206. The angled transition region186 is defined, in part, by the angular distance a measured betweenangled interior surfaces 208 a, 208 b.

FIGS. 10-12 demonstrate flowcharts for methods of operation that may beused for the lint collection systems 10 and 110. Referring to FIG. 10, amethod 220 for general operation is shown. During normal operation, thesystems 10 and 110 may monitor the switch/sensors 28 and 128 todetermine if the level of the surface 7 a of the collected liquid 7 b ishigh (222). Similarly, the systems 10 and 110 may monitor theswitch/sensors 28 and 128 to determine if the level of the surface 7 aof the collected liquid 7 b is low (224). In response to identifyingthat the level of the collected liquid 7 b is high in step 222, thecontrol system 9, 270 may activate the pump 34, 134 to pump out thecollected liquid 7 b and lower the level of the surface 7 a (226). Thecontrol system 9, 270 may monitor the level of the surface 7 aperiodically, until it is determined that the level of the surface isapproximately at a first predetermined threshold.

In response to identifying that the level of the collected liquid 7 b islow in step 224, the control system 9, 270 may control the valve 24, 124to open to pump liquid 7 into the reservoir 14, 114 (228). The controlsystem 9, 270 may monitor the level of the surface 7 a periodically,until it is determined that the level of the surface is approximately ata second predetermined threshold. The control system 9, 270 may continueto monitor the level of the collected liquid 7 b throughout operation ofthe systems 10, 110 to ensure that the level of the collected water 7 bis maintained between the first and second predetermined thresholds.

The method 220 also provides for a flush cycle to clean the reservoirperiodically during operation. The control system 9, 270 may determine atiming of a flush cycle based on a dryer done signal 230. In response tothe dryer done signal in step 230, the control system 9, 270 may check acounter to determine if a predetermined number of drying cycles havebeen completed (e.g. three drying cycles) (232). If the predeterminednumber of drying cycles have not been completed, the control system 9,270 may move to step 224. If the predetermined number of drying cycleshave been completed, the control system 9, 270 may begin a flush cycle(234).

The flush cycle 234 may begin by the controller activating the pump 34,134 to drain the reservoir 14, 114. After the collected liquid 7 b isdrained the control system 9, 270 may supply liquid into the reservoir14 via the nozzles 20, 120 to rinse off lint 6, which has accumulatedagainst the inner walls 16, 116. The rinsing action may force the lint 6to flow to the surface 7 a of the collected liquid 7 b at the bottom ofthe reservoir 14. The control system 9, 270 may continue to activate thepump 34, 134 and control the valve 24, 124 to supply the liquid to rinsethe reservoir 14, 114 for a predetermined period of time.

Upon completion of the flush cycle 234, the control system 9, 270 mayreset the cycle count (236). Following the flush cycle 234, the controlsystem 9, 270 may set a dryer ready signal such that the next dryingcycle may be initiated (238). The method 220 may provide for robustoperation of the systems 10, 110. The operation of the system 10, 110may also contemplate various faults that may occur during operation.

Referring now to FIG. 11, a fault detection method 240 for detecting oneor more faults for the liquid-based lint collection system 10 with thecontrol system 9, 270 is shown. In response to various detectedconditions, the control system 9, 270 may activate a fault or alarm. Forexample, the control system 9, 270 may identify a fault condition inresponse to the pump 34, 134 being active for a predetermined time (e.g.10 or more seconds) without the level of the collected liquid 7 breaching a predetermined level (242). The control system 9, 270 may alsoidentify a fault condition in response to the control the valve 24, 124being open to pump liquid 7 into the reservoir 14, 114 for apredetermined time (e.g. 10 or more seconds) without the level of thecollected liquid 7 b reaching a predetermined level (244).

In some embodiments, the control system 9, 270 may also identify a faultcondition in response to the pump 34, 134 being activated after an awaymode method 260 is performed as discussed in reference to FIG. 12 (246).Additionally, the control system 9, 270 may identify a fault conditionin response to a loss in communication with the switch/sensors 28 and128 (248). In response to the fault conditions 242-248, the controlsystem 9, 270 may determine if a reset switch is on (250).

If the reset switch is on, the control system 9, 270 may activate afault indicator (252). The fault indicator may correspond to anindicator light (e.g. a light emitting diode [LED] light). If the resetswitch is not on, the control system 9, 270 may activate an audiblealarm (254). Once activated, the fault condition of the lint collectionsystem 10, 110 may remain enabled until an authorized servicerepresentative resolves the fault that led to the fault condition.

Referring now to FIG. 12, a method for conditioning the lint collectionsystem 10, 110 for a period of non-use is described as an away modemethod 260. The control system 9, 270 may be requested to initiate theaway mode method 260 in response to the activation of an away switch(262). The control system 9, 270, may then detect if the fan/blower 30is active (264). If the fan/blower 30 is active, the away mode may bedelayed until the fan/blower 30 is inactive. If the control system 9,270 identifies that the fan/blower 30 is inactive, the flush cycle 234may be initialized. Upon completion of the flush cycle 234, the lintcollection system 10, 110 may be placed in a ‘not ready’ mode that mayalso deactivate the dryer 2 (266). In the ‘not ready’ mode, thereservoir 14, 114 may be left empty until the away mode switch isdeactivated. Once the away mode is deactivated, the control system 9,270 may begin normal operation by filling the reservoir to thepredetermined level.

Referring to FIG. 13, a schematic diagram of the control system 270 isshown. The control system 270 comprises a controller 272, which maycorrespond to or more processors or circuits configured to control thelint collection system 10, 110. The controller 272 is powered via apower supply 274 that may be configured to convert and supply power froman AC power source 276. The controller 272 is demonstrated incommunication with the, switch/sensor 28, 128, the valve 24, 124, andthe pump 34, 134. The controller 272 may also be in communication withan operational control switch 278 corresponding the away switch and thereset switch, a speaker 280 configured to output the alarm signal, andan access door switch 282 configured to identify a condition of theaccess door 8.

The controller 272 may comprise a memory, a plurality of relays and/orinput/output (i/o) circuits configured to control the lint collectionsystem 10, 110. As discussed herein, the control system 270 may beintegrated all or in part with the control system 9 for the dryer 2. Thecontrol system 270 may further be in communication with one or moreadditional controllers, which may be configured to track a maintenanceschedule, or control the functions of a plurality of dryers, for examplein a commercial or industrial environment. In this way, the lintcollection system 10, 110 may be integrated with a variety of systems toprovide efficient operation with improved performance.

The following tables demonstrate an exemplary comparison of dryers witha screen filter compared to dryers including a screen-free, liquid basedlint collection system 10, 110 as disclosed herein. The comparisontesting was performed on a 50 lb. gas clothes dryers, including a screenfilter located in an air path between the tumbler and the fan and a 50lb. gas clothes dryers, including a screen-free, liquid based lintcollection system. For Table 1, the lint was collected after four (4),45-minute dry cycles. Table 2 demonstrates drying performance metricsfor a dryer with a conventional screen and Table 3 demonstrates dryingperformance metrics for a dryer with a liquid-based lint collectionsystem 10, 110 as disclosed herein.

TABLE 1 Screen Filter Lint Collection vs. Screen-Free, Liquid-Based LintCollection System 10, 110 Screen-Free, Liquid-Based Screen Filter LintCollection Collection System Mass of lint collected contained within the20.3 25.8 dryer (g) Mass of lint collected at exhaust outlet (g) 24.314.7 Total Mass of Lint Collected (g) 44.6 40.5 Percentage of lintcollected by screen 46% 64% filter collection/screen-free, liquid basedcollection (%)

TABLE 2 Performance Metrics for Dryer with Conventional Screen Filter 50lb Gas Dryer (Conventional Screen) 0.6″ static pressure, 30 min dryingtime Bone Dry Weight (kg) 22.7 Dry Load Retention (%) 1.0% Wet Weight(kg) 36.4 Water Removed (kg) 13.4 Finish Weight (kg) 23 Water RemovalRate (kg/min) 0.447 Burner Efficiency(kJ/kg 4736 water)

TABLE 3 Performance metrics for Dryer with Screen-Free, Liquid-BasedLint Collection System 10, 110 50 lb Gas Dryer (Liquid Lint collection)0.6″ static pressure, 30 min drying time Bone Dry Weight (kg) 22.7 DryLoad Retention (%) 1.4% Wet Weight (kg) 36.4 Water Removed (kg) 13.3Finish Weight (kg) 23.1 Water Removal Rate (kg/min) 0.48 BurnerEfficiency(kJ/kg 4333 water)

As the testing indicates, the percentage of lint collected by the screenfree, liquid-based lint collection system is significantly greater thanthe percentage of lint collected using screen filters alone. Moreover,overall Burner efficiency was improved. As demonstrated, the disclosedliquid-based lint collection system 10, 110 may provide various benefitsover conventional systems utilizing screens for filtration. Theliquid-based lint collection systems 10, 110 as described herein may beconfigured in various combinations based on the teachings of thedisclosure to provide additional benefits without departing from thespirit of the disclosure. In this way, the disclosure provides forflexible systems to improve performance of a filtration system for adryer.

While embodiments and examples of this invention have been shown anddescribed, nothing in this specification should be considered aslimiting. All examples and test data presented are representative andnon-limiting. Moreover, the above described embodiments of the inventionmay be modified or varied, and elements added or omitted, withoutdeparting from the invention, as appreciated by persons skilled in theart in light of the above teachings. It is therefore to be understoodthat the invention is to be measured by the scope of the claims, and maybe practiced in alternative manners to those which have beenspecifically described in the specification without departing from theinventive concepts herein.

The invention claimed is:
 1. A lint collection system, comprising: aninitial air-lint conduit a lint-collection reservoir coupled to theinitial air-lint conduit; a spray assembly configured to spray a liquidinto the lint-collection reservoir; and a sensor that monitors the levelof the liquid collected in the lint-collection reservoir.
 2. The lintcollection system according to claim 1, further comprising a pumpcoupled to the lint-collection reservoir.
 3. The lint collection systemaccording to claim 1, further comprising a blower fluidically coupled tothe initial air-lint conduit.
 4. The lint collection system according toclaim 3, further comprising an air passageway positioned between theair-lint conduit and the fan/blower.
 5. The lint collection systemaccording to claim 1, wherein the blower is configured to force anair-lint combination from a dryer tumbler over the liquid collected intothe lint-collection reservoir.
 6. The lint collection system accordingto claim 1, wherein the spray assembly comprises a plurality of spraynozzles.
 7. The lint collection system according to claim 6, wherein theplurality of spray nozzles are configured to spray the liquid along aplurality of inner walls of the lint-collection reservoir.
 8. The lintcollection system according to claim 6, wherein the plurality of spraynozzles are directed in complementary directions within the reservoirgenerating a rotational flow of the liquid collected in thelint-collection reservoir.
 9. A lint collection system, comprising: asystem chamber, having an inlet that receives an air-lint combinationand defining an interior having a reservoir section and an air flowarea; an interior conduit disposed within the system chamber; a sprayassembly that sprays liquid into the reservoir section; and a sensorthat monitors the level of the liquid collected in the reservoirsection.
 10. The lint collection system according to claim 9, whereinthe interior conduit comprises a stepped entry region, an angledtransition region, and an outlet region.
 11. The lint collection systemaccording to claim 10, wherein the spray assembly comprises at least onespray nozzle disposed in the interior conduit.
 12. The lint collectionsystem according to claim 11, wherein the at least one spray nozzledirects the sprayed liquid to an inner surface of the interior conduit.13. The lint collection system according to claim 9, wherein the sprayassembly comprises a plurality of spray nozzles.
 14. The lint collectionsystem according to claim 13, wherein the plurality of spray nozzles areconnected to inner walls of the lint-collection reservoir.
 15. A clothesdryer, comprising: an outer body, having a hatch door; a tumblerdisposed within the outer body coupled to the hatch door; a screen-free,liquid-based lint collection system, the lint collection systemcomprising: an initial air-lint conduit fluidically coupled to thetumbler; a lint-collection reservoir coupled to the initial air-lintconduit; a spray assembly that sprays liquid into the lint-collectionreservoir; and a sensor that monitors the level of the liquid collectedin the lint-collection reservoir.
 16. The clothes dryer according toclaim 15, wherein the initial air-lint conduit corresponds to aninterior conduit extending at least partially into the lint-collectionreservoir.
 17. The clothes dryer according to claim 15, wherein interiorconduit forms a substantially rectangular shape and extends into thelint collection reservoir having a complementary shape configured toreceive the substantially rectangular shape.
 18. The clothes dryeraccording to claim 17, wherein the receipt of the interior conduit intothe reservoir forms a space channeling the flow of an air lintcombination from the tumbler between the interior conduit and the airlint reservoir.
 19. The clothes dryer according to claim 15, wherein thespray assembly comprises a plurality of spray nozzles.
 20. The lintcollection system according to claim 19, wherein the plurality of spraynozzles are configured to spray the liquid along a plurality of innerwalls of the lint-collection reservoir.